CENTUM VP Distributed Control System

What is a distributed control system?

A Distributed Control System (DCS) is an automated control solution widely used in industrial plant operations. In the instrumentation industry, it’s commonly known as a DCS. Unlike centralized systems, a DCS decentralizes control by assigning controllers to individual pieces of equipment. This approach enhances system reliability and allows for efficient, long-term operation of large-scale plants, while also reducing labor requirements and improving operational efficiency.

Key Features and Benefits

1. Separation of Functions and Risk Distribution
   Operator Interface vs. Controllers:
   The operator interface (used for monitoring and operation) is separate from the controllers (which perform control calculations). This means that if the operator interface fails, the controllers continue to manage the process automatically, ensuring uninterrupted operation.
   Decentralized Installation:
   System components can be installed in various locations throughout the plant. With network connections—such as optical fiber—input/output (I/O) nodes can be placed close to the equipment, significantly reducing field wiring costs.
2. Enhanced Reliability and Maintainability
   Fault Isolation:
   If one controller fails, it does not impact the operation of other controllers. By assigning controllers to individual pieces of equipment, the risk of multiple systems becoming unmonitorable at once is minimized.
   Planned Maintenance:
   Maintenance can be performed on one piece of equipment at a time without disrupting the entire system, supporting continuous plant operation.Integrated Operations

CENTUM VP achieves the Operational Excellence that is the focus of Yokogawa's Production Excellence, Safety Excellence and Asset Excellence initiatives. It offers integrated viewing and data handling functions.

For example, alarms from the ProSafe-RS Safety Instrumented System and Plant Resource Manager, Yokogawa's Asset Management product, can be seen and handled seamlessly in the Human Interface Station (HIS). All plant process data and device data are handled by CENTUM VP.

Easy to Operate with Clear Visibility

Yokogawa offers an intuitive and easy-to-understand HMI environment for plant operation and monitoring, which is the result of vast experience with CENTUM systems in operation. Flexibility in displaying operation windows and monitors helps in adapting to various aspects of operation needs.

CENTUM VP provides easy-to understand graphics based on the ergonomics and knowledge engineering. For instance, data displays are provided with high visibility that enables intuitive awareness of the situation. The use of colors considers the best contrast and environments of the central control room and the configuration of the displays integrates the knowhow of experienced operators. With all these functions, CENTUM VP enables operators to make quick and accurate decisions during operations and contributes to improve operation efficiency.

System Message Banner

Continuously displays the latest alarm messages, keeping operators up to date on process conditions.

Browser Bar

Contains navigation tools for the convenience of operators, frequently-used icons can be grouped in a My Favorites folder.

Window History

Lists the previous operational displays. Operators can quickly call up previously-used graphics windows.

AOG Solution

The AOG (Advanced Operator Graphics) solution emphasizes ergonomic design and seeks, through improved color selection, layout, and visual function, to improve operators situational awareness. A team of Yokogawa engineers visited many plants to conduct a detailed analysis, review the tasks carried out by operators, and learn about the plant's operations. In accordance with general principles on industrial design and human engineering, Yokogawa then redesigned the GUIs for the HMI displays to reduce operator errors, make their work easier to perform, and reduce physical stress.

Trend Recording

By using the Trend Recording function, process data such as temperature, pressure and flow rate coming into the Control Station are gathered by the HIS, and the time-series changes in the process data are displayed in a graph (trend graph).

The HIS trend recording function acquires a variety of trend data types, suitable for a continuous process plant and a batch process plant. The continuous-type data acquisition is suitable for recording and monitoring data for a long period of time. The batch-type data acquisition starts and stops acquiring data according to the commands received from operators. Comparison between the actual data and a reference pattern is also available for the batch-type.

Operation Keyboard

A unique USB keyboard is available for CENTUM VP option. The 64 function keys and the numeric keypad can be used by operators to call up graphics by pressing a single key.

Switching between frame tabs can be done by pressing the container window key. The keyboard has two built-in speakers and the key pitch complies with IEC 9241-11.

A touch sensor highlights the selected operating instrument on the screen to prevent unintentional input errors.

A single-loop operation keyboard and an 8-loop simultaneous operation are available.

Engineering

Yokogawa’s innovative engineering tools provide greater flexibility and up-to-date plant knowledge, resulting in improved ease of use and management within the CENTUM VP distributed control system.

The three smart engineering products - N-IO (The Network I/O), FieldMate Validator, and Automation Design Suite - simplify project management, shorten project duration, and reduce project risk, helping overcome our customers’ toughest challenges.

Flexible I/O Binding with N-IO

Flexible I/O binding is Yokogawa’s improved late I/O binding solution, providing the following benefits:

• Simple and hassle-free I/O binding
• Ability to be modified remotely
• Early delivery of I/O cabinets to the site
• Shortened duration of projects

FieldMate Validator

System Independent Loop Commissioning utilizing the FieldMate Validator is an innovative tool, which allows for field testing validation of N-IO without requiring a deployed system. After the I/O design is fixed, application engineering and hardware engineering can progress independently and parallel.

Automation Design Suite

Yokogawa's new engineering environment, the Automation Design Suite:

• Retains an entire plant's engineering history from design phase to commissioning and live operation, providing up-to-date knowledge with every expansion or change throughout the lifecycle.
• Provides dynamic management of design, investment and project effectiveness by auditing and versioning engineering changes and facilitating effective engineering through ModPacks (Modification Packages). This helps maintain project schedules by reducing the delays and the engineering impact of late design changes or scope changes.
• Auto-documents and checks inconsistencies in project activity and software resources, significantly reducing project risk.

Management of Change and Resources

Download the brochure  to learn more.

Field Digital

Yokogawa realized the potential of field networks in a production control system early on and designed its systems with field networks in mind. CENTUM VP supports FOUNDATION™ fieldbus, HART, PROFIBUS-DP, DeviceNet, Modbus, Modbus/TCP, Ethernet/IP and ISA100.11a wireless. The CENTUM VP integratedly controls and monitors these field devices from various vendors with various communication protocols.

Yokogawa's Fieldbus Related Products

Applying Fieldbus in Plant Control System

The engineering for fieldbus function blocks can be performed in the same way as for other function blocks in FCS. The operation and monitoring environment is also the same for the fieldbus function blocks and other FCS function blocks. No additional requirements for engineering, operation and monitoring of the fieldbus applications in Yokogawa DCS. The most favorable merit for applying fieldbus is highly efficient maintenance of field devices. Yokogawa offers an asset management software package, Plant Resource Manager (PRM), for device management and diagnosis. With PRM, the advantage of fieldbus can be optimized so as to make the maintenance of the whole system more efficient.

Plant Resource Manager (PRM)

The maintenance information of devices are collected by PRM via fieldbuses and stored in the PRM database. The corresponding maintenance schedules, maintenance procedures and spare parts information are also stored accordingly in the same database. The maintenance of the field devices can be performed through fieldbus. Thus the maintenance engineers are considerably relieved from going to the fields of the devices in the remote areas and hazardous areas.

Audit Trail

Audit trail management is important in both control and maintenance systems. All maintenance works on devices, which are maintained by PRM, are recorded and stored, and can be easily retrieved too.

Predictive Maintenance

By integrated management of device management information, the replacement cycle of devices and trend of device troubles can be predicted. This technique minimizes the impact of device problems on plant operation, and maintenance work and parts procurement can also be planned and scheduled.

Solutions to Non-Fieldbus Devices

PRM can create a database for legacy devices in addition to Fieldbus devices. Maintenance information is recorded and managed in a database for integrated, overall planned maintenance of all devices in the plant.

DD and CF Download

The FOUNDATION™ fieldbus device files in this section are categorized according to whether the devices have undergone Host Interoperability Support Testing (HIST). HIST is an invaluable tool in determining whether a specific fieldbus device is interoperable with a host system.

About HIST at Yokogawa

• FOUNDATION™ fieldbus laboratory is established in Yokogawa Singapore.
• Yokogawa is running the HIST program according to the FOUNDATION™ fieldbus specifications.
• Yokogawa is continuing development of HIST in cooperation with other device manufacturers.
• The list of field devices that have passed the HIST can be checked on the Interoperability page.

Interoperability Menu

List of HIST Completed Devices  (Link to Yokogawa Global Website)
List of FIST Completed Devices  (Link to Yokogawa Global Website)

Recommended FOUNDATION™ fieldbus Accessories   (Link to Yokogawa Global Website)

Unified Gateway Station (UGS)

The unified gateway station (UGS) acts as an interface, allowing CENTUM VP to communicate with STARDOM network-based control systems or other third-party subsystems such as Modbus RTUs, Modbus/TCP units, EtherNet/IP units, OPC DA units, and intelligent electronic devices (IEDs). It utilizes the EC 61850 protocol, which has been widely adopted by the power industry.

Unified Gateway Station (UGS)  (0.4 MB) 
IEC 61850 IED Communication Package (for UGS)  (0.4 MB)

System Architecture

Robustness Against Cyber Attack

CENTUM VP field control unit has obtained the ISASecure® Embedded Device Security Assurance (EDSA) certification from the ISA Security Compliance Institute (ISCI). The certification was obtained through a process that involved an examination by the CSSC (Control System Security Center) Certification Laboratory. It ensures that CENTUM is equipped with the cyber security features to be used in the industries such as oil, petrochemical, power and many others.

Security Lifecycle Approach and Service

Yokogawa built its security lifecycle approach upon industry cyber-security standards. And Yokogawa provides an effective security service in response to the customer's requests and operational conditions.

Yokogawa's Global Network

Yokogawa's global network of 25 manufacturing facilities and 88 companies spans 55 countries. Since its founding in 1915, the company has been engaged in cutting-edge research and innovation, securing more than 7,200 patents and registrations.

Yokogawa’s global network of engineering resources is ready to respond whenever and wherever to our customers’ requirements. We take pride in our VigilantPlant mission of realizing the ideal plant for our customers.

Our customers can depend on our service offices and maintenance engineers for support whenever it is needed, at all phases of the plant lifecycle. In line with our VigilantPlant vision for the ideal plant, Yokogawa provides a comprehensive suite of services that ensure safe, reliable, environmentally friendly, and profitable plant operations.

System Software Updates

Periodically, system software must be brought up to date by adding new functions, enhancing existing functions, and fixing bugs. For a variety of reasons, many of our customers would prefer to wait for a scheduled plant shutdown to update their system software to the latest version. Even if a customer has not yet installed an earlier version of the software, Yokogawa guarantees that the system will keep working normally and without interruption when the latest software version is installed. Yokogawa also guarantees that the software will be fully compatible.

System Modification & Expansion

Our customers often need to modify or expand a control system after it is installed, and major concerns with this include avoiding disruptions to plant operations, minimizing the shutdown period, and minimizing the risks of a hot system cutover.

Yokogawa offers a virtual environment for FCS and HIS where both the control and operator functions of the CENTUM database can be tested without FCS hardware. It ensures the new programs will work when they are installed, reduces risks of system failures, and minimizes the shutdown period.

Upgrading

For each of its CENTUM systems, Yokogawa has paid particular attention to helping its customers manage lifecycle costs by optimizing the upgrade process. Upgrading is simple and quick.

All of Yokogawa's legacy CENTUM systems can be controlled and monitored from a newer CENTUM system. Via a control network, CENTUM VP can control and monitor operations at a plant that relies on a CENTUM V, CENTUM-XL, CENTUM CS, or CENTUM CS 3000 system. The latest CENTUM VP can also communicate with both the N-IO and the more traditional FIO and Yokogawa will continue to sell and provide long-term support to both types of I/O. Thus, by allowing its customers to utilize their existing assets wherever possible, Yokogawa offers them a cost-effective way to upgrade their production control systems.

CENTUM's History

Migration

CENTUM has been Yokogawa’s DCS brand since 1975, when the first generation CENTUM system was released to the market. Many of our competitors in the DCS market have either been acquired by other companies or have disappeared from the market together with their control systems. Only a handful of the companies that were first active in this market are still around today.

Not satisfied with another vendor’s control systems? Consider migrating to it to CENTUM VP. We have successfully migrated over 350 non-Yokogawa systems so far and the number is steadily growing. To name a few: Bailey INFI90, Foxboro I/A, Emerson RS3/PROVOX/DeltaV, Eurotherm, Hartman & Brown ContronicP, Hitachi, Honeywell TDC2000/TDC3000/PKS, Siemens SIMATIC, Taylor MODCELL, Toshiba, Allen-Bradley PLC.